CN1988863B - 吸收胶凝材料的间接印刷 - Google Patents
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Abstract
本发明涉及一种通过间接印刷将吸收胶凝材料(AGM)颗粒施加到载体层上的方法,所述载体层用于吸收制品,尤其是婴儿或成人尿布、训练裤、套穿尿布(尿布裤)卫生巾和紧身短裤衬里等。这些制品典型包括具有AGM颗粒的载体层以及构成整个制品的其它层。
Description
技术领域
本发明涉及一种将吸收胶凝材料(AGM)颗粒施加到载体层上的方法,所述载体层用于吸收制品,尤其是婴儿或成人尿布、训练裤、套穿尿布(尿布裤)、卫生巾和紧身短裤衬里等。这些制品典型包括具有AGM颗粒的载体层,AGM颗粒通过与构成整个制品的其它层一起间接印刷而沉积在载体层上。
背景技术
本文所用术语“AGM颗粒”包括与其体积相比能够吸收和储存高含量液体的材料。“AGM”是吸收胶凝材料的缩写。这些材料主要由超吸收聚合物形成。在本文中,AGM材料可作为不同粒度的颗粒使用,包括粉末状材料或粉末材料与不同粒度或形式(例如纤维)的颗粒的混合物。
这种AGM材料通常被嵌入熔喷纤维或纤维素纤维(或类似的纤维材料及其组合)的吸收垫内,或者直接沉积到非织造材料的载体层上。本发明适用于这两种方法。这种“吸收制品”可以例如用于制造尿布、卫生巾或甚至任何种类的液体收集制品。
人们已提出了各种用于获得在底物上具有预先确定的图案和厚度轮廓的AGM颗粒分布的方法。这些方法包括通过导管将空气载送的AGM颗粒和纤维的混合物吹到真空转筒上。这种方法仅允许对AGM在其所分布表面上的图案和厚度分布进行有限的控制。
特别是在吸收芯含有低含量纤维素纤维或不含任何纤维素纤维而仅具有AGM颗粒作为唯一的液体储存材料的情况下,相对于形状和隐密性而言,AGM颗粒的精确分布十分重要。
在这种情况下应当指出,采用单片或多片芯、一层AGM或相互堆叠或相互并列的多个层都是可能的。这也允许在不同的层中使用不同的AGM。因此,所得产品变型的可能性几乎是无限的。然而,颗粒的高精度分布是重要的。
发明内容
因此,本发明涉及一种通过间接印刷而将AGM颗粒以高精度的分布、图案和AGM材料在表面上的含量施加到表面上的方法。该方法可用于施加AGM颗粒,这一施加AGM颗粒的过程要求将颗粒或粉末在载体层上精确地、象印刷一样地定位。一个具体的应用可以是包括用于一次性尿布的芯或这类芯的一些部分的主要为AGM/胶水的制造。
根据本发明的第一个实施方案,本发明间接印刷方法的特征在于:
-AGM颗粒被转移装置从AGM颗粒的大容量储存器中拾起,
-所述转移装置在其表面具有凹槽,凹槽的数目、尺寸和位置决定被转移装置拾起的AGM颗粒的量和图案,
-转移装置可从大容量储存器移动到载体层通过的位置(转移或相遇的位置),
-提供用于在转移装置往所述相遇(或转移)位置移动期间将所述AGM颗粒保持在所述凹槽内的部件,
-并且提供有用于在所述转移位置将所述AGM颗粒排出到载体层上的部件。
本发明还涉及一种设备,具体地讲涉及一种用于实施本发明方法的设备。
在下文中,间接印刷是指在与载体层接触之前从AGM的大容量储存器中分离出来的AGM的转移。直接印刷是指在与载体层接触之前AGM不从AGM的大容量储存器中分离出来。这不包括在本发明范围内。
本发明提供一种显著提高AGM沉积精度的方法和设备。目前所达到的标准偏差已降低至用先进的现有技术所达到的标准偏差的约1/4。因此,可获得沿横向和纵向具有AGM精确分布轮廓的尿布芯。本发明的方法尤其让AGM颗粒以高精度沉积在以每秒1米至每秒3米的表面速度快速移动的载体层上,载体层表面速度优选最高为每秒5米,或甚至每秒10米,并且甚至更优选最高为每秒15米。由于AGM颗粒沉积的精度,本发明可制造例如没有纤维素或类似的吸收和/或亲水纤维的尿布吸收芯,这导致极薄的吸收芯和在制品使用时改进的舒适感与贴合性。
本文所用术语“转移装置”包括能够以确定的形状和厚度轮廓拾起AGM颗粒并将这些颗粒沉积在载体底物上而不改变其构型的任何活动构件。
转移装置的优选实施方案是成型的转筒或辊子,在本文中也称为“印刷辊”或“转移辊”,因为AGM颗粒图案的转移可与印刷相比较。另一个实施方案可以是在其表面具有凹槽并被在大容量AGM颗粒储存器与转移位置之间移动的移动带。
本文所用术语AGM颗粒的“批量”或“大容量储存器”是指任何种类的颗粒供给源,尤其是料斗。
“保持部件”被提供用于将由转移装置的凹槽拾起的AGM颗粒在从批量至转移位置的移动期间保持在这些凹槽中,在转移位置这些颗粒被传递到载体层上。在一个优选的实施方案中,保持部件是在从批量至转移位置的路径上被沿转移装置的表面导向的带,所述转移装置尤其是印刷辊。其它尤其优选的可能实施方案是用于将AGM颗粒保持在凹槽内的真空部件。也可采用静电场。
本文所用术语“排出部件”是指在上述定义的转移位置将AGM颗粒传递到载体底物上的部件。传递颗粒时,颗粒可由空气喷射排出,或者由静电场或仅靠重力排出。
附图说明
通过以下参照附图的说明可更好地理解本发明以上和进一步的特征、方面和优点。
图1表示本发明的一个实施方案;
图2是表示图1所示实施方案中附加细节的示意图;
图3表示图2所示实施方案的改型;
图4对应于图2,其一个特征进行了改型;
图5仍对应于图2,其一个特征进行了改型;
图6仍对应于图2,其一个特征进行了改型;
图7表示图3和6组合的一个实施方案;
图8表示本发明用于实现本发明方法的设备的另一个实施方案;
图9是图10所示本发明另一个实施方案沿线9-9的横截面;
图10是从图9左侧看的前视图。
具体实施方式
图1表示装有批量AGM材料12的料斗10。料斗10具有上侧的进料口14和底部的递送口16。料斗构成本发明中称为“批量”的一个实施方案。
印刷辊18以围绕开口16的料斗底部紧随辊子18轮廓的方式进入料斗10的开口16,以防止AGM颗粒意外掉落。
印刷辊18在其表面上具有孔和凹槽22,它们填充有来自料斗10中AGM材料12批量下端20的AGM颗粒,而辊子18的表面通过料斗10内部的AGM材料12。选择凹槽22的数目、尺寸和位置,使得凹槽的体积和图案对应于将被印刷辊接收并转移到载体层上的AGM材料的目标图案和厚度轮廓,如下文所解释。
印刷辊18构成本发明转移装置的一个实施方案。另一个实施方案例如可由在其表面具有用于接收AGM材料的凹槽的带构成。
然而,可旋转的印刷辊可为优选的实施方案。
当转移辊18上的凹槽22之一位于该装载位置时,AGM颗粒被印刷辊18的凹槽22拾起。在从料斗10至本文中称为“转移或相遇位置”的途中,AGM颗粒被保持在这些凹槽中,在转移或相遇位置图1中逆时针旋转的印刷辊18位于正好在载体层24表面对面的位置。载体层24由旋转的支撑辊25支撑。
例如,载体层是AGM颗粒从印刷辊排出或卸载(靠重力)到其上的非织造纤维网。为了将AGM颗粒保持在载体层24上,优选在位于印刷辊18与载体层24之间的转移位置的上游将胶水喷洒到载体层24上,该上游位置由参考数字26表示。由于在该上游位置26胶水被施加到载体层24上,因此AGM颗粒被保持在载体层24上。用于将AGM颗粒保持在载体层24上特别优选的胶水是微纤维胶水,这种胶水具有由通过相应的细喷嘴喷射热熔粘合材料而制成的很细的纤维。这类喷嘴可商购自美国乔治亚州Dawsonville市的Nordson Company。
支撑辊25优选也将AGM颗粒保持在载体上,特别是靠使用通过形成支撑辊25圆柱表面的筛网的压差(真空)。可供选择地,支撑辊也可由移动的带提供。在位于印刷辊18与载体层24之间的转移位置下游的另一个位置(该位置由28表示),胶水优选但可选择地喷射到载体层24的AGM颗粒上。该胶水也优选为微丝胶水,象纤维一样进入AGM颗粒之间,以将整个沉积物保持在一起。在一个可供选择的实施方案中,也可采用将胶水载送到AGM颗粒上的覆盖层。
当在位置26和/或28施加大量的胶水时,采用低残余粘合剂积累或没有残余粘合剂积累倾向的材料制造圆柱形支撑辊表面是有利的。这可为TeflonTM涂敷的表面,或者如果用带代替支撑辊,那么可为硅橡胶材料。特别是当载体层24被暴露在支撑辊内侧的真空中的情况下,支撑辊的表面可由硅橡胶筛网制成,优选由金属加强。
如图1所示,在该具体实施方案中,通过辊子沿图1中箭头标示的逆时针方向转动,印刷辊18移动通过AGM材料,AGM颗粒被拾在辊子的凹槽22中,但自然存在一些风险,超出这些填充凹槽之外的多余AGM颗粒被带出在印刷辊18表面与料斗底部相邻边缘之间的料斗。因此,在该边缘提供有刮削部件19,其一个实施例如图2所示。
在图2中,已结合图1描述过的那些构件或元件以相同的参考数字表示。
图2中的刮削部件19由刮刀30构成,它具有与印刷辊18表面紧密接触的刮削边缘32。在刮刀30与印刷辊18之间的距离应大于0毫米,以防止过大的压力或对设备与AGM颗粒造成损坏。当选择刮削刀片距离时,颗粒尺寸混合是要考虑的因素之一。例如,平均直径在900微米及以上的非常大的AGM颗粒应需要小于900微米的间隔。适用间隔的上限应为约1毫米,优选间隔介于0.01和0.5毫米之间,更优选介于0.03和0.1毫米之间,以保证在延长的生产运行下的良好刮削。
图3表示对应于图2所示实施方案的实施方案,但附加表示保持部件,保持部件用于在从料斗10至转移位置的途中将AGM颗粒保持在提供于印刷辊18表面的凹槽(未示出)内。
将AGM颗粒保持在凹槽内的一种可能性可为施加到印刷辊18内侧与在凹槽底部的吸孔(未示出)组合使用的真空。如图3所示保持部件的另一个实施方案由环形带34构成,环形带随着印刷辊18的旋转沿其表面从紧靠刮刀下游的位置移动至紧靠转移位置上游的位置,在转移位置颗粒被转移到载体层24上,如图3所示。带被驱动环绕在邻近印刷辊18的带路径上下位置的上下导辊36,38,并环绕与印刷辊表面间隔开的第三导辊,与其它导辊36,38形成一个三角形。可通过驱动这三个辊子之一来驱动带34,以在箭头所示的方向移动带34。可供选择地,带可空转并通过与印刷辊18的表面接触而被移动。
图4表示图2和3中刮削部件19的一个可供选择的实施方案。对于对应部分,图2和3中的参考数字也用于图4中。代替图2和3中的刮刀,图4所示的实施方案提供有安排在图2和3中刮刀30位置并在与印刷辊18表面移动方向相反方向的压力下喷射空气的空气喷射箱40,如图4所示,以保持AGM颗粒从空气喷射箱与印刷辊18表面之间的间隔返回。
图5所示的实施方案还是基本对应于上述图2至4所示的实施方案,它表示刮削部件19的另一个改型,在这种情况下刮削部件由在上述刮刀位置的转刷42构成,以通过沿逆时针方向的旋转而保持AGM颗粒不离开料斗10。
图6又表示刮削部件19的另一个实施方案,在这种情况下刮削部件由环绕上下导辊46,48运转的活动带构成,上下导辊之一可由适合的驱动装置(未示出)来驱动。带44在AGM材料一侧基本垂直向上移动,如箭头所示,并且在料斗10的外侧向下返回。
带44提升料斗10内侧的AGM材料,以保持AGM材料不通过印刷辊表面与带44之间的间隔而离开料斗。
图7表示的实施方案基本为图3和6实施方案的组合,包括用于将AGM颗粒保持在印刷辊凹槽内的带34和具有结合图6所述刮削部件功能的另一条带44。
图8表示其料斗50被制成为用于将AGM颗粒保持在浮动状态的流化床的实施方案。在这种情况下,由18表示的印刷辊转动通过流化的颗粒,流化颗粒被印刷辊18表面的凹槽拾起。
伸出凹槽或粘附到凹槽外印刷辊18表面上的AGM颗粒被用作刮削部件并且就布置在标号为55的相遇位置上游的刮刀54从印刷辊上剥离,在这种情况下,印刷辊就设置在由放下的转筒支撑的载体层24对面。在相遇位置上下游的位置26,28有定位胶水头56,58,其用于将胶水施加到在位置26的载体层24上和在位置28被施加到载体层上而沉积的AGM颗粒上。在这种情况下,印刷辊从顶部浸没到AGM大容量储存器中。
在优选的实施方案中,图8所示的系统还包括空气载送的颗粒循环系统51,52,57。在该系统中,颗粒被从靠近相遇位置55的位置沿导管51,52在箭头53所示方向传送到返回导管末端57。这样防止颗粒由于在流化床那个区域的搅拌减少而粘附或停留在相遇位置55的区域。颗粒循环系统通常可靠在管道中的空气流来工作以沿导管传送颗粒。
图9表示一个间接颗粒印刷工位,它包括连接到定子外壳68的AGM供给源70,72,74和离心辊子60,离心辊子具有沿图9中从左至右的水平线的自身轴线80。图9是沿图10中线9的横截面视图,图10表示图9所示颗粒印刷工位的侧视图。在图10中,AGM所沉积的载体被表示为在传送转筒上,也称为支撑辊25(部分示出)。离心辊子60包括圆柱形的中心部分62和两个沿轴向位于其两侧的锥台形进口部分64,66。进口部分64,66与由被分为两个支管72,74的供给管70构成的AGM供给系统68相连接,支管在它们的轴端与离心辊子60的进口部分64,66相连接。因此,AGM被通过供给管70供给到支管72,74内,并在进口部分64,66被离心力传送,最后进入离心辊子的中心部分62。在该位置,AGM离开离心辊子和定子68,并且仍然被离心力所建立的压力压在网版印刷辊82的内侧,网版印刷辊外侧部分地被带86覆盖。
该印刷辊在周壁上提供有形成适合形状和尺寸的图案的开口(未示出),在离心辊子每次旋转时AGM颗粒通过这些开口离开印刷工位并且无接触地沉积到载体层24上(如图10所示)。
Claims (15)
1.一种用于将吸收胶凝材料颗粒间接地施加到载体层上的方法,所述载体层用于吸收制品,所述制品包括所述载体层以及另外的层,所述方法包括以下步骤:
-吸收胶凝材料颗粒被转移装置从吸收胶凝材料颗粒的散状储存器中拾起,
-所述转移装置在其表面具有凹槽,所述凹槽具有吸收胶凝材料表面和相对的内侧,其中所述凹槽的数目、尺寸和位置决定被所述转移装置拾起的吸收胶凝材料颗粒的量和图案,
-所述转移装置从邻近所述散状储存器的装载位置移动到所述载体层邻近所述转移装置的相遇位置,
-提供用于在所述转移装置往所述相遇位置移动期间将所述吸收胶凝材料颗粒保持在所述凹槽内的部件,其中用于将所述吸收胶凝材料颗粒保持在所述转移装置的所述凹槽内的所述部件包括施加到印刷辊内侧与在凹槽底部的吸孔组合使用的真空,
-并且提供用于在所述相遇位置将所述吸收胶凝材料颗粒排出到所述载体层上的部件。
2.如权利要求1所述的方法,其中在所述相遇位置的上游在吸收胶凝材料颗粒在所述相遇位置从所述转移装置沉积到所述载体层上之前将胶水施加到所述载体层上。
3.如权利要求2所述的方法,其中将胶水施加到在所述相遇位置下游沉积到所述载体层上的所述吸收胶凝材料颗粒上。
4.如权利要求2或3所述的方法,其中所述胶水是微纤维胶水。
5.如权利要求1所述的方法,其中将载有胶水的覆盖层施加到在所述相遇位置下游的所述吸收胶凝材料颗粒上。
6.如权利要求1所述的方法,其中所述转移装置是转移辊,所述转移辊在其表面上具有所述凹槽。
7.如权利要求1所述的方法,其中所述载体层通过传送带或旋转支撑辊送往或载离所述相遇位置。
8.如权利要求1所述的方法,其中用于将所述吸收胶凝材料颗粒从所述转移装置排出到所述载体层上的所述部件包括空气喷射部件。
9.如权利要求1所述的方法,其中所述吸收胶凝材料容纳在具有开放底部的料斗内,所述转移装置通过所述开放底部,其中所述吸收胶凝材料颗粒靠重力填充所述转移装置的所述凹槽。
10.如权利要求1所述的方法,其中所述吸收胶凝材料散状储存器是包括吸收胶凝材料颗粒床并具有开放顶部的容器,所述转移装置通过所述开放顶部,使得所述转移装置伸入所述吸收胶凝材料颗粒床内,以使所述吸收胶凝材料颗粒通过向印刷辊内侧施加真空与在凹槽底部的吸孔组合使用而提升到所述转移装置中的所述凹槽内。
11.如权利要求1所述的方法,所述方法还使用刮削部件,所述刮削部件用于阻挡吸收胶凝材料颗粒被所述转移装置移动超过填充所述凹槽的体积所需的量。
12.如权利要求11所述的方法,其中所述刮削部件由刮刀构成,所述刮刀至所述转移装置的距离大于0毫米,并且最大至1毫米。
13.如权利要求1所述的方法,其中所述吸收制品是尿布。
14.实施权利要求1-3中任一项所述方法的设备,所述设备包括用于从吸收胶凝材料颗粒的散状储存器中拾起吸收胶凝材料颗粒的转移装置,所述转移装置在其表面上具有凹槽,所述凹槽的数目、尺寸和位置决定被所述转移装置拾起的吸收胶凝材料颗粒的量和图案,所述转移装置从所述散状储存器移动到所述载体层通过所述转移装置的位置。
15.如权利要求14所述的设备,其中所述转移装置是旋转辊。
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PCT/US2005/026238 WO2006014854A1 (en) | 2004-07-28 | 2005-07-25 | Indirect printing of agm |
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Also Published As
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AU2005269573B2 (en) | 2009-10-29 |
EP2238953A2 (en) | 2010-10-13 |
CN1988863A (zh) | 2007-06-27 |
EP2292199A1 (en) | 2011-03-09 |
JP5128642B2 (ja) | 2013-01-23 |
ATE464034T1 (de) | 2010-04-15 |
PL2238953T3 (pl) | 2013-10-31 |
ES2343955T3 (es) | 2010-08-13 |
CA2575465C (en) | 2010-12-07 |
ES2397213T3 (es) | 2013-03-05 |
EP1621165B1 (en) | 2010-04-14 |
PL2292199T3 (pl) | 2013-03-29 |
MX2007001001A (es) | 2008-10-24 |
EP2238953B1 (en) | 2013-06-19 |
US7838722B2 (en) | 2010-11-23 |
WO2006014854A1 (en) | 2006-02-09 |
CA2717303A1 (en) | 2006-02-09 |
AU2005269573A1 (en) | 2006-02-09 |
EP2238953A3 (en) | 2011-08-17 |
US20110017398A1 (en) | 2011-01-27 |
JP2010246990A (ja) | 2010-11-04 |
ZA200700387B (en) | 2008-08-27 |
EP2292199B1 (en) | 2012-10-10 |
KR20070029272A (ko) | 2007-03-13 |
US20060024433A1 (en) | 2006-02-02 |
US8735645B2 (en) | 2014-05-27 |
EP1621165A1 (en) | 2006-02-01 |
CA2717303C (en) | 2012-05-29 |
CA2575465A1 (en) | 2006-02-09 |
PL1621165T3 (pl) | 2010-09-30 |
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